Fuel filter

ABSTRACT

A fuel filter assembly includes a filter housing defining a cavity, a center stack having a base component and a top portion. The center stack is positioned within the cavity of the filter housing and attached to the housing, the center stack having an axial aperture in the top portion, the axial aperture having a circumferential surface, and a fuel filter. The fuel filter includes a filter base, an end cap having a top surface and a bottom surface opposite the top surface, an axial extension that extends from the bottom surface, and at least one prong attached to the axial extension, the at least one prong having an axial surface facing away from the top surface that axially locates the fuel filter in the housing against the circumferential surface, a filter element attached to the bottom surface of the end cap, and a pin attached to a filter base.

TECHNICAL FIELD

The present disclosure relates to a fuel filter for an internalcombustion engine of a motor vehicle.

BACKGROUND

Fuel filters can be found in any motor vehicle that includes an internalcombustion engine, and serve for filtering out different contaminantsfrom the fuel such as water and solid particles, as examples.Contaminants may include water and particulates, as examples.

Particulates, for instance, can be introduced into the fuel stream in avariety of ways, such as dirt or rust while filling the tank, or fromthe fuel itself if from an unfiltered source. Particulates can beabrasive and can cause rapid wear and failure of engine components, suchas the fuel pump and injectors. Filters often therefore typicallyinclude a particulate filter element (i.e., paper), which allows passageof the fuel (and any water present), while capturing the particulatematter.

Water in the fuel can result in corrosion or impairment of engineperformance. If water gets into a moving part, such as an injectorvalve, the part can overheat or wear excessively, leading to early lifefailure of the engine. Or, water can cause rust and corrosion if presentin the fuel stream. Particular attention is therefore paid to filteringout water from the fuel to be combusted. Water content is generallypresent to some extent in all fuels, but can be high in modern biofuelssuch as, for example, biodiesel, because biofuels can be hygroscopic(i.e., water absorbing). Thus, often fuel particulate filters arecombined with water separators to achieve low particulate with minimalwater content.

Due to its greater density than fuel, separated water may be collectedin suitable water collection chambers of the water separator and may beperiodically discharged. Often, because of the density differencebetween water and fuel, the water separator is located at the base of afilter element, which may thereby include a particulate filter element(i.e., paper) and a water separator. And, although water separated fromthe fuel may typically be discharged via a valve (either on a regularlyscheduled basis, or based on a sensed amount of water), the paperportion of the filter element may become clogged with particulate, whichcan result in decreased engine performance.

As such, fuel filters are typically changed at regular intervals duringthe life of the engine as routine maintenance. However, routine changingof filters can inadvertently damage the engine if not installedproperly. Some filter designs include insertion devices to aid in theinsertion of filters into a housing. For instance, fuel filters mayinclude an axially protruding pin that is used to close a run-offchannel. The pin fits snugly within the channel and typically includesan O-ring or other sealing element to prevent drainage during engineuse. Fluid access to the channel occurs when the pin is removed from thechannel (i.e., by pulling out the filter from its cavity). Thus,installation of such a filter includes proper alignment of the pin withthe channel. In some known designs the pin is visually aligned with thechannel. However, it may be difficult to see or “feel” such alignment,and if a proper technique is not developed, the pin or filter may bedamaged during installation.

One known design for aligning the pin in the channel includes using aspherical ramp that the pin rests against while the filter is rotated. Arun-off or receiving channel is positioned at the end of the ramp, suchthat the pin passes off the ramp and into the channel during manualrotation of the filter. However, although such designs have beeneffectively used for years, such a design may include impartingexcessive rotational torque to the filter during its installation.Friction on the ramp, or simply improperly using the pin-rampcombination, can thereby result in stress being introduced to the pin orother components of the filter during installation.

For instance, careless installation may include pressing down on thefilter, which can put pressure on the pin while the pin is slid alongthe channel. The pin may thereby miss or overshoot the channel, or insome instances the pin can become bound up against the ramp. In anextreme example, it is possible for the pin to snap off, which not onlyruins the filter, but may also leave the pin behind within a cavitywhere the filter is to be installed. Worse yet, if the pin snaps offwithin the channel, then engine repairs may be necessary to remove thebroken pin from the channel.

Filters may be damaged during installation for other reasons, as well.For instance, if components do not properly align in an axial direction,then tolerance stack-ups may result in improper axial location ofcomponents and improper sealing or fitting with other mating componentsof the housing or cavity in which the filter is placed. Radial play ofthe filter with respect to its housing can result in axial misalignmentof the pin within its channel, or angular misalignment of the filter inthe housing. Filters may also be cocked with respect to the housing, aswell, which can cause the filter to bind up within the housing and causedamage.

Thus, a seemingly simple and relatively inexpensive operation ofinstalling a filter can include challenges that can result in costlydamages. Because of the generally routine nature of filter installationand even after many such installations, vehicle owners, mechanics orengine repair technicians may thereby install a filter in such a fashionthat can include damage not only to the filter, but to the engine aswell.

As such, there is a need to for an improved design and method ofinstalling a fuel filter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a fuel filter according to the disclosure;

FIG. 2A shows a cross-sectional view of the fuel filter of FIG. 1;

FIG. 2B is a plan view of a sword of FIG. 2A;

FIG. 3A shows a center stack according to the disclosure.

FIG. 3B shows a back side of a top portion of the center stack of FIG.3A

FIG. 3C shows a plan or top view of the top portion shown in FIG. 3B;

FIG. 4A represents a first profile that is a circumferential view of thepin;

FIG. 4B represents a second profile that is a radial view of the pin;

FIG. 5 shows an end cap of the fuel filter of FIG. 1.

FIG. 6 is a symbolic representation of a fuel system that includes thefuel filter of FIG. 1;

FIG. 7 shows a cross-sectional view of the fuel filter and having thecenter stack positioned therein.

FIG. 8 shows the fuel filter in a housing;

FIGS. 9A through 9E show progressive steps of assembly of the centerstack of FIG. 3A into the fuel filter of FIG. 1;

FIG. 10A shows a cross-sectional view and dimensional information foraligned filter and center stack;

FIG. 10B is a graphical illustration of the fuel filter misaligned dueto tolerance stackup;

FIG. 11A is a side view of the end cap engaged with the top portion ofthe center stack;

FIG. 11B shows a side view of the fuel filter and showing a relevantaxial dimension for assembly;

FIG. 12 is a plan view of the bottom of the fuel filter; and

FIG. 13 is a plan view of the bottom of the fuel filter.

DETAILED DESCRIPTION

Reference in the specification to “an exemplary illustration”, an“example” or similar language means that a particular feature,structure, or characteristic described in connection with the exemplaryapproach is included in at least one illustration. The appearances ofthe phrase “in an illustration” or similar type language in variousplaces in the specification are not necessarily all referring to thesame illustration or example.

FIG. 1 shows an exemplary fuel filter 100 according to the disclosure,and FIG. 2A shows a cross-sectional view of fuel filter 100. Fuel filter100 includes an exemplary end cap 102, a filter element 104, a waterseparator 106, and a pin 108, with a transition piece 110 that extendsbetween filter element 104 and water separator 106 and supports waterseparator 106. In one example and as will be discussed, water separator106 may not be present, such as in an application when a water separatoris not used or present in fuel filter 100. In such an example a spacemay be provided so that fuel filter 100 thereby occupies the samefootprint or profile. Filter element 104 includes a hole or opening 112at its base, passing through water separator 106 and a filter centersupport 114. Water separator 106 includes pin 108 for positioning withina channel of a housing, as will be further discussed. A center line 116defines a central axis of fuel filter 100. Filter center support 114includes a first portion 118 that includes a first wall 120 that is at afirst radial dimension 122, and a second portion 124 that includes asecond wall 126 that is at a second radial dimension 128, with secondradial dimension 128 less than first radial dimension 122. An annular orconical surface 130 extends between first portion 118 and second portion124, forming a stepped portion 132 therebetween. A sword 134 ispositioned at stepped portion 132 and spans from first wall 120 tosecond wall 126.

FIG. 2B is a plan view of sword 134. Sword 134 extends along an innersurface 136 of conical surface 130. Sword 134 also extends to eitheraxial side of inner surface 136. Sword 134 is positioned at an angularorientation, as viewed from above or below fuel filter 100, and withrespect to pin 108, so that pin 108 (see e.g., FIG. 1) finds its hole ina housing when sword 134 is positioned within a slot, as will bediscussed. First portion 118 includes an inner surface 144.

Referring again to FIG. 2A, a filter base 146 includes an inner diameter148 and a bottom surface 150. Water separator 106 is positioned at thebottom of fuel filter 100 and in one example is attached to transitionpiece 100. That is, generally, water separator 106 is positioned betweenbottom surface 150 and filter element 104. Water separator 106 includesan annular, hydrophobic diaphragm 138 arranged in a similar orientationas filter element 104, and which is generally permeable for fuel but isgenerally impermeable for water. Fuel filter 100 includes an inner seal140 that includes sealing slots 142.

FIG. 3A shows a center stack 200, according to the disclosure. Centerstack 200 is sometimes also referred to as a functional carrier. Centerstack 200 includes a radial extension 202 and a top portion 204 aboveradial extension 202 that is proximate to a fuel access aperture 206.Top portion 204 includes a slot 208 that extends upward from radialextension 202 to an upper end 210 of center stack 200. FIG. 3B shows aback side of top portion 204 of FIG. 3A, so slot 208 is not visible inFIG. 3B. Top portion 204 includes a curved surface 212 that extendsabout and forms a circumference of upper end 210. Curved surface 212 iscurved such that it extends axially upward from slot 208, where itbegins at a minimum axial height 214, and as curved surface 212 passesor extends circumferentially and to either side of slot 208, curvedsurface 212 forms a maximum axial location 216 at a location 180°removed from slot 208, which in turn defines minimum axial height 214. Aplan or top view of top portion 204 and curved surface 212 is shown inFIG. 3C, having center stack 200 with slot 208 and maximum axiallocation 216 opposite slot 208 and about curved surface 212. A flatcircumferential surface 218 is inboard of curved surface 212 and anaperture 220 is inboard of flat circumferential surface 218.

Referring again to FIG. 3A, center stack 200 includes an extendedportion 222 that extends from radial extension 202 to a center stackbase 224, extended portion 222 having an outer surface 226. A basecomponent 228 includes attachment locations 230, illustrated as holes,for attachment of center stack 200 to a structure such as a filterhousing. A fuel discharge port 232 is at the base of center stack 200. Acenter stack center line 234 defines a central axis of center stack 200.Radial extension 202 includes an outer diameter 236 that defines anouter surface 238 of radial extension 202, and defined about centerstack center line 234.

Referring to FIG. 2A and FIG. 3A, inner seal 140 of fuel filter 100 ismade of a flexible material such as plastic, and inner seal 140 engageswith center stack base 224 when fuel filter 100 is installed within ahousing. Inner seal 140 includes sealing slots 142 that provideflexibility to inner seal 140 such that a seal is formed that preventsliquid from passing thereby. That is, inner seal 140 includes an innerdiameter such that a minor interference is formed between inner seal 140and center stack base 224.

FIGS. 4A and 4B show orthogonal views of pin 108 attached to waterseparator 106 and having a point 400. FIG. 4A represents a first profilethat is a circumferential view of pin 108, and FIG. 4B represents asecond profile that is a radial view of pin 108.

Pin 108 includes a groove 402 for an O-ring, a shaft 404, a first lip406, and a second lip 408. Groove 402 is formed between first lip 406and second lip 408, and an O-ring 410 may be positioned therebetween andin groove 402. As illustrated, pin 108 includes two sets of fins thatextend from second lip 408 to point 400. First fins 412 are visible inprofile in FIG. 4A, and second fins 414 are visible in profile in FIG.4B. First fins 412 extend along a single flat 416, whereas second fins414 include axial portions 418 and angled flats 420. Thus, FIG. 4Arepresents a first profile 422 that is a circumferential view of pin108, and FIG. 4B represents a second profile 424 that is a radial viewof pin 108. Further, although point 400 is referred to as a point, it iscontemplated that point 400, according to one aspect, includes agenerally flat surface that is formed at the confluence of first fins412 and second fins 414.

FIG. 5 shows end cap 102. End cap 102 includes, in the illustratedexample, three prongs 500 that extend both axially and radially. It iscontemplated, however, that more or less than three prongs may be used,and that only one may be used to sufficiently axially locate end cap102. Prongs 500 each include respective circumferential surfaces 502that, in one example, are flat. End cap 102 includes an endcapundersurface 504. A top surface 506 includes engagement features 508 forengagement of a cover (not shown) with fuel filter 100. Engagementfeatures 508 engage with features on an underside of the cover andcapture fuel filter 100 during installation into a housing. An axialextension 510 extends from an underside 512 of end cap 102 and isintegral thereto. Axial extension 510 includes a groove 514 for anO-ring, and the axial extension is positioned within a hole or aperture240 as seen in FIG. 3C.

FIG. 6 is a symbolic representation of a fuel system that includes afuel filter, such as fuel filter 100, and its components positionedtherein. FIG. 7 correspondingly shows a cross-sectional view of fuelfilter 100 and having center stack 200 positioned therein for discussionpurposes.

A fuel supply system 600 for an internal combustion engine 602 includesfuel filter 100 for removing contaminants that may include solidparticles and water. The solid particles, or sediment, and the water areseparated from a fuel to be supplied to internal combustion engine 602for combustion. Flow direction of fuel in fuel supply system 600 isillustrated by corresponding arrows in the various flow lines. Fuelfilter 100 includes filter element 104 for particulate filtration whenarranged in a filter outer housing, not shown, which is penetrated by aflow in a radial direction 604 from a raw end 606 to a particle-free end608. Fuel filter 100 includes water separator 106 which is arranged, inone example, gravitationally below filter element 104, and which isformed as the illustrated annular filter.

Water separator 106 includes annular, hydrophobic diaphragm 138 which isarranged in a similar orientation as filter element 104, and which isgenerally permeable for fuel but is generally impermeable for water.Thus, water present in the fuel is coalesced or collected at hydrophobicdiaphragm 138 and upon reaching a certain drop size is discharged asprincipally discharged water 610, but may include some fuel, downwardand to a second water separator 612. Water-free and sediment-free fuel614 (pure fuel) thereby passes via a fuel line 616 to internalcombustion engine 602.

Discharged water 610, including some fuel, passes to second waterseparator 612, which is connected in series to water separator 106 andis formed in a smooth-flow manner and arranged below first waterseparator 106. Second water separator 612 is illustrated in fuel supplysystem 600 and separate from fuel filter 100. Smooth-flow means in thiscase that discharged water 610 flowing through second water separator612 flows laminarly, that is, without turbulence and thus allowsseparation of the water from any fuel passing therethrough. Waterseparated in second water separator 612 is collected in a watercollection chamber 618 and is drained as needed.

Discharging fuel from second water separator 612 takes place by means ofa pressure differential present or generated in fuel supply system 600.For example, fuel in fuel supply system 600, which in this example ispressurized, can be discharged via a throttle device 620 into a lowpressure or pressure-less return line 622 passing to a fuel tank 624.Additionally or alternatively to this, discharging fuel from secondwater separator 612 can take place via a venturi nozzle ejector pump(not illustrated) arranged in an inlet line, such as return line 622, offuel filter 100. It is contemplated that flow in second water separator612 remains laminar, which is the case if an amount of discharged fuelfrom second water separator 612 is much smaller than flow through fuelfilter 100 and water separator 106.

Depending on the size and flow through fuel filter 100, a flow throughsecond water separator 612 which is lower by a factor of approximately1/20 to 1/200, in one example, provides good conditions for a laminarflow and depending on the flow passageway dimensions, etc . . . It iscontemplated, however, that the desired flow characteristics may bepresent in different flow arrangements and that laminar flow may beachieved with other designs and conditions of operation. Waterdischarged through water collection chamber 618 may be controlled viaone, or more than one (such as for redundancy), valves.

Thus, in operation, raw fuel (which may contain water and/or sediment)passes from fuel tank 624 and to raw end 606. The raw fuel passesradially 604 and inwardly through filter element 104, wherein sedimentor particulate is removed via filter element 104. At this stage in theflow, water present generally passes through filter element 104 toparticle-free end 608, and thus a particle-free fuel-water mixturethereby flows from particle-free end 608 downward to water separator106. The fuel-water mixture encounters hydrophobic diaphragm 138, andpressure in the particle-free fuel-water mixture thereby causes fuel topass through hydrophobic diaphragm 138, but the hydrophobic nature ofhydrophobic diaphragm 138 prevents water from passing through. As such,water-free and sediment-free fuel, or pure fuel 626, passes throughhydrophobic diaphragm 138, while generally water passes as discharge 610into a discharge aperture 628. Discharge 610 includes fluid thatencountered and did not pass through hydrophobic diaphragm 138, which isgenerally water, but a substantial fraction of fuel may also be present.

Water-free and sediment-free fuel 626 passes radially inward and afterhaving passed through hydrophobic diaphragm 138. Water-free andsediment-free fuel 626 thereby encounters inner seal 140 which iscompressed against center stack base 224 and due to the minorinterference therewith. Because of the sealing effect, little if anywater-free and sediment-free fuel 626 passes through the seal formed.However, should any water-free and sediment-free fuel 626 pass thereby,it will join with discharged water 610 and ultimately pass back to fueltank 624, where it will pass again to fuel filter 100. Thus, anyinadvertent leakage of water-free and sediment-free fuel through innerseal 140 will not result in lost fuel.

Discharge 610 thereby passes to second water separator 612 where furtherseparation of fuel and water occurs. Primarily water is discharged atwater collection chamber 618, and any remainder (having some fuel)passes via throttle device 620 to fuel tank 624, whereby it again passesthrough filter supply system 600.

Referring back to FIGS. 2A and 3A, within fuel filter 100 andparticularly center stack 200, pure fuel 626 passes toward outer surface226 of center stack 200 and along inner surface 144 of filter centersupport 114, is directed upward, toward, and then into fuel accessaperture 206, thereby passing into a hollow center of extended portion222, and passing to fuel discharge port 232 and then to internalcombustion engine 602 via fuel line 616.

Center stack 200 and fuel filter 100 include assembly features describedherein. As seen in FIG. 3A, center stack 200 includes extended portion222 and fuel access aperture 206. Extended portion 222 includes a hollowcenter (not visible) that passes from fuel access aperture 222, throughthe hollow center, and to an exit or fuel discharge port 232.

FIG. 8 shows fuel filter 100 within a housing 800. Housing 800 includesa housing base 802 having walls that define a cavity, and a cover 804.Cover 804 includes threads 806, and housing base 802 includes threads808. When fuel filter 100 is installed into housing 800, cover 804provides a sealing effect, and center stack 200 is positioned therein.Housing 800 includes a channel 810, into which pin 108 fits when filter100 is properly aligned with housing 800, providing a sealing effect.

FIGS. 9A through 9E show progressive steps of an illustrative assemblyof the fuel filter into its housing. Such assembly includes positioningfuel filter 100 into housing 800, but the housing is not shown in FIGS.9A-9E solely for illustration purposes. When fuel filter 100 isinstalled within its housing, an important feature is that the two items(i.e., fuel filter 100 and housing 800) be rotationally oriented withrespect to each other so that pin 108 is positioned within itscorresponding hole (not shown) within housing 800. To do so, a uniqueset of features is provided, according to the disclosure, which ensuresproper orientation of the filter to properly align pin 108 with its holeand to avoid damage to any of the components. Assembly of fuel filter100 onto center stack 200 proceeds as follows.

During assembly, center stack 200 is positioned within a cavity of ahousing element and may be part of the housing, but as indicated abovethe housing is not shown for illustration purposes. Referring to FIG.9A, at its base and in water separator 106, pin 108 extends downwardfrom fuel filter 100 and is attached to water separator 106. Top portion204 of center stack 200 extends upward and toward opening 112 of fuelfilter 100. Curved surface 212 having maximum axial location 216 isthereby positioned to enter opening 112 when fuel filter 100 isinstalled within housing 800. FIG. 9B illustrates fuel filter 100 as itpasses onto and over center stack 200, and as top portion 204 of centerstack 200 extends into and along inner surface 144 of center support114. Radial extension 202 includes outer diameter 236 that approximatelymatches with inner surface 144 of filter center support 114.

Curved surface 212 is positioned to engage against sword 134 as fuelfilter 100 passes onto and over center support 114. However, becauseinstallation is performed without the installer (i.e., a person holdingfuel filter 100 and passing it onto center stack 200) havingline-of-site or being able to see the respective orientations, curvedsurface 212 engages with sword 134 so that fuel filter 100 is ultimatelyproperly installed regardless of its initial angular orientation basedon the continued following steps.

As seen in FIG. 9C, fuel filter 100 is installed to the point wherecurved surface 212 engages against sword 134. As can be seen, however,because of interference between curved surface 212 and sword 134,further insertion of fuel filter 100 is stopped. However, also becausecurved surface 212 is curved, fuel filter 100 is thereby caused torotate 900. That is, as filter 100 continues on its axial path, oncesword 134 engages against curved surface 212, a rotational moment isimparted upon fuel filter 100, and fuel filter 100 begins to rotate 900,as shown in FIG. 9D and at a subsequent further rotation seen in FIG.9E.

FIG. 9E shows fuel filter 100 at an angular orientation in which sword134 of fuel filter 100 is aligned with slot 208 of center stack 200.Having slot 208 aligned with sword 134 thereby, by default, aligns pin108 with its channel 810 in housing 800 so that pin 108 can thereby bepressed into channel 810, completing the installation of fuel filter 100in housing 800.

Thus, in overall summary of installation and with respect to FIGS.9A-9E, fuel filter 100 may be installed in its housing in such a fashionthat, regardless of its beginning or initial angular orientation, curvedsurface 212 of center stack 200 will engage axially with sword 134 ifthe two are not yet, by happenstance, already aligned. That is, in mostassembly procedures pin 108 will not be aligned with its channel 810 inhousing 800, and engagement of curved surface 212 with sword 134 willthereby occur. Once sword 134 and curved surface 212 engage, the motionof such engagement against the angled or curved surface thereby causesrotation 900 to occur, until sword 134 is aligned with slot 208.

Further, because of the position of maximum axial location 216, it iscontemplated that rotation 900 may be in the angular direction asillustrated, or it may be in the opposite angular direction depending onwhich side of maximum axial location 216 that curved surface 212 engageswith sword 134. Curved surface 212 extends downwardly to either side ofmaximum axial location 216. Thus, if sword 134 engages curved surface212 on one side of maximum axial location 216, then rotation 900 will bein one direction, and if sword 134 engages curved surface 212 on theother side of maximum axial location 216, then rotation will be in theopposite direction.

During assembly of fuel filter 100 onto center stack 200, damage canoccur to the fuel filter or housing if components do fit properly or ifinterference fits occur, and which is avoided according to thedisclosure. For instance, as discussed, when sword 134 engages with slot208 of center stack 200, pin 108 is thereby pressed into its passagewayor channel 810 in housing 800. Thus, if pin 108 is not properly alignedwith channel 810, an interference can occur which can lead to damage ofcomponents if filter 100 is then forced into its location.

Also, during assembly, components are axially aligned so that componentsof the filter assembly fit into the housing, but without unintentionallyengaging with the housing—which can also lead to damage. Likewise, ifcomponents do not fit radially with one another, damage can occur tocomponents if, again, the filter is forced into its location against aninterference.

In addition, fuel filter 100 includes features that prevent inadvertentcocking within the housing, to avoid binding of fuel filter 100 duringinstallation. Accordingly, as seen in FIG. 2A, filter base 146 includesinner diameter 148 that is selected in conjunction with outer diameter236 of radial extension 202 so that radial extension 202 can passthrough inner diameter 148 during installation. Fuel filter 100 includesfuel filter center line 116 and center stack 200 includes center stackcenter line 234, as will be discussed.

As such, according to the disclosure and as shown in FIGS. 10A and 10B,radial extension 202 is positioned within inner surface 144 of centerstack 200 and having a clearance therebetween that is nominally selectedto minimize any radial clearance and also minimize the propensity forthe fuel filter to cock or fall off kilter when in its housing. FIG. 10Ashows related dimensional information for fuel filter 100 positionednominally over center stack 200 (and with center lines 116, 234aligned). FIG. 10B is a graphical illustration of fuel filter 100positioned over center stack 200, but with center lines 116, 234 offsetand angled from one another and based on a ‘worst case’ cocking ofcomponents due to misalignment as well as tolerance stack up, but thatdo not result in damage to any of the component parts according to thedisclosure.

Inner surface 144 is at a bore or inner diameter 1000, thereby includinga radial clearance 1002 that is a gap between outer diameter 236 ofradial extension 202 and bore diameter 1000 when center lines 116, 234are aligned. Filter base 146 of fuel filter 100 having inner diameter148 fits over center stack base 224 having a base outer diameter 1004.Accordingly, a radial base gap 1006 is between inner diameter 148 andbase outer diameter 1004. In other words, outer diameter 236 of radialextension 202 is nominally undersized from bore diameter 1000, resultingin radial clearance 1002 for components, even when center lines 116 and234 are aligned. Base component 228 includes a groove 1018 for filterbase 146.

Tolerances for component fabrication may be selected based on knowntolerancing techniques such as geometric dimensioning and tolerancing(GDT), root sum square (RSS) analysis, or based on six sigmatolerancing, as examples. As such, according to the disclosure,tolerance fits at a first axial location 1008 between inner surface 144and bore diameter 1000 are selected to meet appropriate manufacturingrequirements, such as to meet 3 sigma, 4 sigma, or greater fits toensure that radial clearance 1002 remains positive under moststatistical conditions when many thousands of component parts arefabricated and fit together Likewise, inner diameter 148 and base outerdiameter 1004 at a second axial location 1010 are also selected to meetstatistical requirements so that radial base gap 1006 remains positive,as well.

During assembly, and as discussed, pin 108 is rotationally aligned withrespect to housing 800 due to engagement of sword 134 with slot 208.Accordingly, pin 108 according to the disclosure includes point 400 thatensures pin 108 will enter its channel 810 within housing 800. Pin 108is positioned or positionable within channel 810 and according to thedisclosure pin 108 aligns with channel 810 under any worst-case scenarioof statistical extremes that are achieved based on manufacturingtolerances of all relevant component parts. Thus, as seen in FIG. 10Aand having component parts aligned on their respective centers, pin 108having a center line 1012 aligned with channel 810 having a center line1014.

Referring to FIG. 10B, center lines 116, 234 may be canted oroff-alignment with one another due to each being on extremes of theirtolerance ranges and during installation. That is, before axialextension 510 is positioned within hole 240 of center stack 200. Forinstance, outer diameter 236 of radial extension 202 may be on a low endof its tolerance band, and bore diameter 1000 may be at an upper end ofits tolerance band, which may result in a maximum gap 1016 being formedwhen radial extension 202 is pressed to one extreme against innersurface 144 of center stack 200. Likewise, and again at an extreme, baseouter diameter 1004 may be at a low end of its tolerance band whileinner diameter 148 of fuel filter 100 may be at its maximum tolerance,which may result in a maximum gap 1016 being formed when filter base 146is pressed against center stack base 224.

As such, when fuel filter 100 is positioned within filter housing 800,fuel filter 100 contacts center stack 200 at first axial location 1008,and fuel filter 100 contacts center stack base 224 of center stack 200at second axial location 1010.

And, when filter base 146 is pressed or tilted against center stack base224 at second axial location 1010 and in a direction that is 180° offfrom that at first axial location 1008, then under this conditiontolerance stackup may result in a worst case tilt of fuel filter 100with respect to center stack 200 during assembly, with maximum gap 1016formed at one circumferential location 1008 and maximum gap 1016 formedat a different circumferential location 1010 that is 180° offsettherefrom. As such, and according to the disclosure, point 400 of pin108 is properly dimensioned to ensure that under even the worst case oftolerance stack up and misalignment of components, pin 108 will findchannel 810 during assembly, such as when pin center line 1014 does notalign perfectly with channel center line 1012.

Center line 116 illustrates a center of fuel filter 100, and center line234 illustrates a center line of center stack 200, and the extremes ofmisalignment of both center lines 116, 234 are shown in FIG. 10B. And,because of the flexible nature of inner seal 140 and its minorinterference with center stack base 224, any misalignment of fuel filter100 and center stack 200 may thereby be tolerated and inner seal 140will seal with center stack base 224 regardless of any misalignment dueto radial tolerance stackups and misalignments of components.

Thus, with point 400 of pin 108 properly dimensioned, and taking intoaccount the extremes of tolerances within the relevant components, point400 under all circumstances will align with and enter channel 810 duringassembly, while sealing of components is ensured.

As seen between the FIGS. 4A and 4B, the illustrated profiles aredifferent from one another and according to the disclosure. That is,because of the radial alignment/tolerance aspects of fuel filter 100 andas described with respect to FIGS. 10A and 10B, the correspondingprofile of pin 108 as seen in FIG. 4A is long and narrow. In contrast,because of the rotational installation of fuel filter 100 within housing800, as fuel filter 100 rotates about, and with the engagement of sword134 with curved surface 212, as described, rotation occurs until sword134 engages with slot 208, and until pin 108 engages with channel 810.Accordingly, the corresponding profile of pin 108 in FIG. 4B is shorterand more blunt.

As illustrated, fuel filter 100 includes end cap 102, shown also inFIGS. 5, 11A, and 11B. End cap 102 includes features that axially locatefuel filter 100 with respect to housing 800, which includes axiallylocating filter base 146 with respect to a base component 228 of centerstack 200. As can be seen in the figures, such as FIG. 10A, basecomponent 228 includes a circumferential clearance region or groove 1018that is proximate and radially external to center stack base 224 andinto which filter base 146 is positioned.

As discussed, base outer diameter 1004 fits within filter base 146, andas illustrated in FIG. 10B, misalignment of components may result inmaximum gap 1016. As such, groove 1018 is likewise sized or tolerancedsuch that sufficient radial space is present within groove 1018 toaccommodate all such axial movement and misalignment of filter base 146with respect to center stack base 224.

FIG. 5 is a cutaway of end cap 102, with engagement of prongs 500 with asurface of center stack 200 shown in view FIG. 11A. FIG. 11B shows aside view of fuel filter 100 and showing a relevant axial dimension forassembly. Each prong 500 includes a respective axial surface 502.Correspondingly, as seen in FIG. 3C, top portion 204 includes flatcircumferential surface 218 that is inside of top portion 204. As such,during assembly of fuel filter 100 onto center stack 200, fuel filter100 is pressed into position or otherwise installed to the point thataxial surface 502 of each of prongs 500 engages against flatcircumferential surface 218.

In addition, however, component parts are designed having proper stackup of dimensional tolerances to ensure that filter base 146 does notextend axially and to the point, when assembled, that there is axialinterference between bottom surface 150 and groove 1018. Thus, accordingto the disclosure, component parts include sufficient tolerance toensure that a gap 1020 is formed between parts.

Thus, referring back to FIG. 9E, component parts have not yet engagedaxially and prongs 500 are not situated inside of top portion 204. Assuch, although not shown in FIGS. 9A-9E, it is understood that axialextension 510 is pressed into hole or aperture 240 within top portion204 that is visible in FIG. 3C, axial extension 510 having an O-ringthat engages with hole or aperture 240 and seals to prevent gas or otherleakage from passing thereby. Thus, a final installation step iscompleted, in which axial extension 510 and the O-ring are positionedwithin hole or aperture 240 and during such installation, because pin108 is aligned with its channel 810 via the engagement of sword 134 withslot 208. Because axial surfaces 502 of prongs 500 engage with flatcircumferential surface 218, fuel filter 100 is thereby axiallypositioned with axial surfaces 502 providing a reference point fromwhich axial tolerances of fuel filter 100 are established, according tothe disclosure. A space or clearance 1100 above flat circumferentialsurface 218 provides sufficient axial and radial clearance such thatcurved surface 212 of upper end 210 of center stack 200 may bepositioned therein and without interference.

Axial surfaces 502 of end cap 102 thereby provide a base reference framefrom which axial tolerances are established so that under all conditionsof manufacturing tolerances that may be experienced during fabricationof all relevant components, no axial interference will occur betweenbottom surface 150 of filter base 146. That is, having axial surfaces502 form a base or reference frame, end cap undersurface 504 is therebytolerance-controlled from axial surfaces 502. A dimension within fuelfilter 100 is thus determined based on a dimensional distance from axialsurfaces 502 to end cap underside 512, and from there to bottom surface150 (FIG. 11B). Dimensional distance 1102 thereby extends from axialsurfaces 502 to bottom surface 150. Correspondingly, and referring toFIG. 10A, because flat circumferential surface 218 supports axialsurfaces 502, and because filter base 146 fits into groove 1018 but suchthat bottom surface 150 does not contact groove 1018, gap 1020 isensured, while taking into account all tolerance stackups betweencomponents during manufacturing and assembly of all components.

In such fashion, each profile 422, 424 of pin 108 includes surfaces asshown that correspond favourably with installation and tolerancestackups that may occur in fuel filter 100 and center stack 200. Forinstance, as fuel filter 100 is rotated about curved surface 212, as pin108 engages with channel 810 it is profile 424 that is relevant, in thatpoint 400 finds channel 810 readily and as sword 134 engages with slot208. Accordingly, a more blunt profile as seen in profile 424 favourablycombines with the fit of sword 134 with slot 208 to ensure that bothsets of features engage at the same time. On the other hand, profile 422is more relevant to any radial mis-alignment of components that mayoccur, and as described with respect to FIGS. 10A and 10B. As such, alonger and flat, single flat 416, thereby accommodates more favourablyany misalignment of components. As such, and according to thedisclosure, pin 108 includes two profiles, where profile 422 includessingle flats 416, and profile 424 includes both axial portions 418 andangled flats 420.

FIG. 12 is a plan view of the bottom of fuel filter 100 and showingbottom surface 150. As seen therein, pin 108 includes first ribs or fins412 that extend radially, and second ribs or fins 414 that extendcircumferentially. Prongs 500 are visible, as well as sword 134. As seentherein and according to the disclosure, fuel filter center line 116extends through the center of fuel filter 100, and pin 108 includespoint 400 that extends along a radial line 1200 from point 400 to fuelfilter center line 116. Sword 134 also extends in a radial direction andalong a sword radial line 1202. Sword 134 is thereby offset an angle1204 that, in one example, is approximately 15° from radial line 1202.However, angle 1204 may be any angle, such as 0°, 30°, 90°, or 110°, asexamples.

The angular relationship between sword 134 and pin 108 thereby defines acorresponding angular orientation between channel 810 and slot 208 ofcenter stack 200. In such fashion, it is contemplated that differentdesigns of a fuel filter, for different applications, may therefore bedesigned having a different angular orientation of components, which maybe known as a “poka-yoke” to ensure that the wrong component is notinstalled into a housing. For instance, one fuel filter may be designedfor a particular housing and with a particular angular orientation ofcomponents as illustrated in FIG. 12. However, another fuel filter foran entirely different vehicle may likewise be designed with the samehousing. For this second or alternate design, although the fuel filtermay physically fit within the housing, such filter may not functionproperly in a different engine. Or, having the wrong filter mayalternatively cause damage to the engine. Thus, a housing may bedesigned having a particular center stack, such as center stack 200, andwith an appropriate set of mating features for locating the fuel filteraccording to the disclosure. But, if the wrong filter is installed, thena sword-slot alignment with respect to a given channel-pin may result inavoiding the wrong filter from being installed. For instance, referringto FIG. 13, a plan view of the bottom of fuel filter 100 includes aradial line 1300 extends through a center of pin 1302 and through acenterline 1304. A sword 1306 is positioned, in one example, 77.5°offset 1308 from radial line 1300, or complementarily 102.5° offset 1310therefrom. In the illustrated example, offset 1310 is 102.5° as shown,and in one example it is contemplated that sword 1306 is offset within+/−2.5° of the illustrated angle 102.5°.

With regard to the processes, systems, methods, heuristics, etc.described herein, it should be understood that, although the steps ofsuch processes, etc. have been described as occurring according to acertain ordered sequence, such processes could be practiced with thedescribed steps performed in an order other than the order describedherein. It further should be understood that certain steps could beperformed simultaneously, that other steps could be added, or thatcertain steps described herein could be omitted. In other words, thedescriptions of processes herein are provided for the purpose ofillustrating certain arrangements, and should in no way be construed soas to limit the claimed invention.

Accordingly, it is to be understood that the above description isintended to be illustrative and not restrictive. Many applications otherthan the examples provided would be upon reading the above description.It is anticipated and intended that future developments will occur inthe arts discussed herein, and that the disclosed systems and methodswill be incorporated into such future arrangements. In sum, it should beunderstood that the invention is capable of modification and variation.

All terms used in the claims are intended to be given their broadestreasonable constructions and their ordinary meanings as understood bythose skilled in the art unless an explicit indication to the contraryin made herein. In particular, use of the singular articles such as “a,”“the,” “said,” etc. should be read to recite one or more of theindicated elements unless a claim recites an explicit limitation to thecontrary.

What is claimed is:
 1. A fuel filter assembly, comprising: a filterhousing having an outer wall defining a cavity; a center stack having abase component and a top portion, wherein the center stack is positionedwithin the cavity of the filter housing and attached to the filterhousing, the center stack having an aperture in the top portion and acircumferential surface; and a fuel filter that includes: a filter base;an end cap having a top surface and a bottom surface opposite the topsurface, an axial extension that is integral to and extends from thebottom surface at a first end to a groove at a second end of the axialextension opposite the first end, and at least one prong attached to theaxial extension, the at least one prong having an axial surface facingaway from the top surface that axially locates the fuel filter in thefilter housing and against the circumferential surface of the centerstack, the axial surface located between the bottom surface and thegroove, and the second end engages with the aperture of the center stackfor sealing between the fuel filter and the center stack; a filterelement attached to the bottom surface of the end cap; and a pinattached to a filter base.
 2. The fuel filter assembly of claim 1, thebase component of the center stack having a top surface and the filterbase including a bottom surface, an axial gap being formed between thetop surface of the base component of the center stack and the bottomsurface of the filter base.
 3. The fuel filter assembly of claim 1,wherein the end cap includes a space above the axial surface to provideclearance for an upper end of the center stack.
 4. The fuel filterassembly of claim 3, wherein the base of the filter includes a waterseparator at the filter base.
 5. The fuel filter assembly of claim 1,wherein the pin includes a first set of fins and a second set of finsthat are orthogonal to the first set of fins, wherein a profile of eachof first set of fins is different from a profile of each of the secondset of fins.
 6. The fuel filter assembly of claim 1, further comprising:wherein the fuel filter further includes the filter element having a rawend and a particle free end for fuel flow, and a hydrophobic diaphragm;and wherein the center stack has a fuel access aperture and a fueldischarge port.
 7. The fuel filter assembly of claim 1, wherein thecircumferential surface is flat.
 8. The fuel filter assembly of claim 1,wherein the axial surface of the at least one prong is flat.
 9. The fuelfilter assembly of claim 1, wherein the fuel filter further includes asword for circumferentially locating the fuel filter with respect to thecenter stack, and the axial surface is located between the end cap andthe sword.
 10. The fuel filter assembly of claim 1, further comprisingan O-ring in the groove.
 11. The fuel filter assembly of claim 1,wherein the second end includes a groove, and the second end extendsinto the aperture such that the groove is contained within the aperture.12. A method of installing a fuel filter into a filter housingcomprising: positioning a center stack within a cavity of the filterhousing; positioning the fuel filter such that an axial surface of thefuel filter engages with a circumferential surface of a center stack inthe filter housing to axially locate the fuel filter within the filterhousing and with respect to the center stack, the fuel filter having anend cap with an axial extension that is integral thereto, wherein theaxial extension fits into an aperture of the center stack of the filterhousing and the axial extension engages the fuel filter with the centerstack to seal between the fuel filter and the center stack.
 13. Themethod of claim 12, further comprising: attaching a filter element to anundersurface of the end cap; positioning a water separator at a filterbase of the fuel filter; engaging the filter base with a base componentof the center stack; and attaching a pin to the water separator.
 14. Themethod of claim 13, further comprising forming an axial gap between atop surface of the base component and a bottom surface of the filterbase.
 15. The method of claim 12, wherein the axial extension includes agroove, and positioning the fuel filter further comprises positioningthe fuel filter such that the groove is contained within the aperture.16. The method of claim 15, further comprising positioning an O-ring onthe groove.
 17. The method of claim 15, wherein the axial extensionincludes at least one prong, and the axial surface is an axial surfaceof the at least one prong, and positioning the fuel filter furthercomprises positioning the fuel filter such that the axial surface of theat least one prong engages with the circumferential surface of thecenter stack.
 18. The method of claim 17, wherein the at least one prongincludes three prongs.
 19. The method of claim 18, further comprisingengaging an O-ring of the axial extension with a hole of the upper endof the center stack.
 20. A fuel filter, comprising: a filter base; anend cap having a top surface and a bottom surface opposite the topsurface, an axial extension that extends from and is integral to thebottom surface of the end cap and axially locates the fuel filteragainst a circumferential surface of a center stack, the axial extensionengaging with an aperture of the center stack for sealing between thefuel filter and the center stack, the center stack positioned within acavity of a filter housing and attached to the filter housing; a filterelement attached to the bottom surface of the end cap; a water separatorat the filter base; and a pin attached to the water separator.
 21. Thefuel filter of claim 20, further comprising: a filter center supporthaving a first portion extending along a first axial length; and asecond portion extending along a second axial length; wherein the firstportion includes a first inner diameter that is greater than a secondinner diameter of the second portion, and having a first inner contactsurface at the first inner diameter that radially locates the fuelfilter within the filter housing; and wherein the center stack ispositioned within the filter housing and attached to the filter housing.22. The fuel filter of claim 20, wherein an axial gap is formed betweena top surface of the filter housing and a bottom surface of the filterbase; and wherein the center stack is positioned within the filterhousing and attached to the filter housing.
 23. The fuel filter of claim20, wherein the axial surface engages with an upper surface of thefilter housing to axially locate the fuel filter in the filter housing;and wherein the center stack is positioned within the filter housing andattached to the filter housing.
 24. The fuel filter of claim 20, whereinthe axial surface is flat.
 25. The fuel filter of claim 20, wherein theaxial extension extends from the bottom surface at a first end to agroove at the second end of the axial extension opposite the first end,the axial surface located between the bottom surface and the groove. 26.The fuel filter of claim 25, further comprising an O-ring in the groove.27. The fuel filter of claim 20, wherein the axial extension includes atleast one prong attached to the axial extension, the at least one pronghaving an axial surface facing away from the top surface that axiallylocates the fuel filter against the circumferential surface of thecenter stack.
 28. The fuel filter of claim 27, wherein the at least oneprong includes three prongs.
 29. The fuel filter of claim 27, whereinthe axial extension includes a groove that is contained within theaperture.